2002 Ford Expedition Problems

What owners report

Owners of this model year most often describe spark plugs ejecting from the cylinder heads of the 4.6L/5.4L V8, and a second large group concerns fires and smoke traced to the speed control deactivation switch area near the master cylinder. Complaints also cover seat belts that unlatch on their own, transmission shifting trouble and brake wear or pedal issues. Many of these reports come in above 80,000 miles, and several describe sudden failures while driving or parked.

1. 1
   Engine cooling

   Spark plug ejection from cylinder head

   • 92 complaints (27%)
   • median 97,433 mi at 8.2 yrs old (87 state mileage)
   • 6 mention a crash, fire or injury
   • owner-quoted repair $806 (median of 22 quotes)
   • filed 2005–2017

   Owners describe a loud pop or boom from the engine followed by rough running, loss of power or misfire, after which a spark plug (and sometimes the coil) is found ejected from the cylinder head with stripped threads. Repairs range from rethreading the hole with an insert to replacing the head or coil, and complaints say dealers declined warranty coverage on these repairs. Several owners also report fuel smell and worry about fire risk from an exposed, still-firing plug. Reported from about 66,000 to 182,000 miles, most commonly in the 90,000-160,000 range and often during normal driving.

   3 related service bulletins

   What to check: Ask whether any spark plugs or coil-on-plug units have been replaced and whether thread inserts were installed; listen for a ticking or pinging noise at start-up and check for a fuel smell under the hood.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Ford Expedition and have now twice in the last 6 months have had to have it repaired for the spark plug ejection fro, the motor. The vehicle gave way with its power right in the middle of the intersection. I feel this is a defect and that Ford should take some ownership, it only has 75 thousand miles on it.”

   NHTSA complaint #10277512, filed 2009-07, 75,000 miles

   “Spark plug popped out my iginition coil and the threading section is stripped. When I started my car an exploration sound occurred. Also, my driver side head light won't stay lite even with replacement light unit. Also car stalls when car is facing down a hill, even with a full tank of gas.”

   NHTSA complaint #10669326, filed 2014-12, 155,000 miles
2. 2
   Vehicle speed control

   Smoke or fire at the speed control switch / master cylinder

   • 91 complaints (27%)
   • median 100,000 mi at 8.2 yrs old (71 state mileage)
   • 62 mention a crash, fire or injury
   • owner-quoted repair $813 (median of 9 quotes)
   • filed 2003–2024

   Complaints describe smoke, burning smell or flames from under the hood, often while the vehicle is parked or shortly after driving, with fire departments and mechanics pointing to the speed control deactivation switch on the master cylinder. Some owners report the vehicle was destroyed and that they had not received recall notification or that parts were unavailable when they tried to have the recall done. Others describe cruise control inoperative, erratic idle or unintended acceleration. Spread from roughly 35,000 to 185,000 miles, frequently on vehicles parked overnight or soon after being shut off.

   Recall 05V388000

   What to check: Ask whether recall 05V388000 was completed and whether the switch or its harness has been replaced; check the area around the brake master cylinder for melted or discolored wiring and confirm cruise control works.

   2 excerpts from owner complaints in NHTSA records

   “My vehicle was functioning fine. I ran an errand, came home , parked my 2002 Ford Expedition under the parking shed and went into the house. Not over 45 minutes later my younger sister came and told me that my car was sparking and smoking. When I went to check on my truck I could see smoke and flames. I ran into the house to get the fire extinguisher and used it to put the fire out. …”

   NHTSA complaint #10325002, filed 2010-04, 148,782 miles

   “On the early morning of july 2, 2005 a fire started in our 2002 Ford Expedition. This has subsequently been confirmed by the houston fire department and 2 independant consultants retained by our insurance company. They indicated that the cause of the fire was the cruise control brake deactivation switch. The fire destroyed both of our vehicles and our home. The total damages are estimated at approximately $650,000. …”

   NHTSA complaint #10128231, filed 2005-07, 35,000 miles
3. 3
   Engine

   Transmission slipping, harsh or delayed shifts

   • 11 complaints (3%)
   • median 54,943 mi at 4.2 yrs old (11 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2015

   Complaints describe the transmission slipping, failing to stay in gear, or slamming into gear, sometimes with the overdrive light flashing and shifting in and out on the highway. Owners report sensor replacement, fluid and filter service, and concerns that the transmission itself was not replaced; one report notes water in the transmission after service. Reported from about 27,000 to 160,000 miles, including low-mileage vehicles.

   What to check: Test drive at highway speed and watch for the overdrive light, delayed engagement when shifting from park to drive, and any shudder around 45 mph.

   2 excerpts from owner complaints in NHTSA records

   “My 2002 Ford Expedition od light flashes on and off. I was driving down i75 and my transmission kept shifting in and out of gear.. My whole trip. It slammed into gear almost causing me to loose control of my vehicle. This transmission is definitely a safety hazard. It does not do it all the time seems like when we hit bumps in the road.”

   NHTSA complaint #10318257, filed 2010-03, 110,000 miles

   “May 04, my vehicle transmission was serviced (filter changed and fluid replaced) by the local Ford dealer. In june 04, under 1,000 miles since the service, my vehicle began to vibrate in the rear end when it would shift around 45 m.p.h.and was returned to the Ford dealer who diagnosed the problem as water in the trasmission. The filter was replaced at my expense and the problem has progressed over the last two months. …”

   NHTSA complaint #10088499, filed 2004-08, 36,045 miles
4. 4
   Brakes

   Brake drag, wear and pedal problems

   • 17 complaints (5%)
   • median 83,000 mi at 6.5 yrs old (11 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2002–2024

   Owners describe grinding or rough pedal feel with uneven pad wear suggesting a sticking caliper, brakes that did not engage when parking on a hill, and brake fluid leaks with the warning light on after prior recall work. Some report the dealer replaced cables, rotors and pads at the owner's expense. Reported from around 30,000 to 185,000 miles, including normal driving conditions.

   What to check: Check pad wear on both sides of each front rotor for unevenness, look for fluid leaks at the master cylinder, and test the parking brake on a slope.

   2 excerpts from owner complaints in NHTSA records

   “Brake pedal felt rough upon stepping on pedal (I have a little more than 30k miles on the vehicle) I do work on my own vehicles and I am very knowlegable when it come to basic repairs I inspected both roters on the front of the vehicle and found the driver side inner pad completely worn to the metal the outer pad still has approximately 1/4 inch before it hits the indicator obviously my caliper is sticking I have an appointment tomorrow im curious what tey will say.”

   NHTSA complaint #10053147, filed 2004-01, 31,500 miles

   “2002 Ford Expedition: right front brake(s) making grinding noise when driving and is exaggerated when braking. Called dealer to schedule service. Asked service advisor why wear indicator(s) did not work. Service advisor informed me that Ford has not installed brakes with wear indicators for years. I told the service advisor that it is unbelievable that a $30k vehicle would not have bps with wear indicators especially since my 1992 vw jetta has brake pads with wear indicators. …”

   NHTSA complaint #10041277, filed 2003-10, 39,500 miles

Buying note. On this model year, prioritize a pre-purchase inspection that pulls at least one spark plug and confirms whether recall 05V388000 was completed, since the two most-reported problems are head thread damage and the speed control switch. Ask for records on transmission service, seat belt buckles and brake work, and treat any fuel smell or underhood smoke history as a reason to look further before purchase.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.